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On 11 Mar 2005 at 21:16, Toby Erkson wrote: > Pictures: http://www.icbm.org/erkson/gallery/stock_muffler_fixes > > The right upper exchanger actually came OFF the muffler so that was > welded to the muffler after all other welds were made. Those welds were: > 1. Cracks welded up on heat shield and small one on muffler body. Note that one some makes of mufflers, the heat shield is actually brazed to the muffler body, so you can't always weld there, but rebrazing works well. > 2. Tack welds on upper exchanger-to-exhaust joint to keep from working > loose. The tin around those upper HEs is thin, so I'd recommend something there to slow down the rust. > 4. Flanges welded to lower muffler-to-exchanger pipe that was pre-welded > there as a 'fix'. I had to cut them in 1/2 to remove the exhaust system > in the first place. I really like the idea of adding flanges to those lower joints, but I've never done it myself. I'm always worried that I won't be able to duplicate it the next time around when THIS muffler has to be replaced. Do you think that will be any problem? Are these flanges just standard muffler shop items? > 5. Bolted it all up and then tack welded the right upper exchanger. > Removed it all and welded the upper exchanger to the muffler I hope you just welded the muffler to the HE threaded "nut." Otherwise you have a big problem next time the muffler needs to be replaced. -- ******************************* Jim Adney, jadney@vwtype3.org Madison, Wisconsin, USA ******************************* ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~